Safety and Protection
Exothermic Process
The Exothermic Process is an effective and safe method of welding copper to copper or copper to steel for the purpose of producing permanent
electrical connections. Exothermically welded connections are produced from the energy and molten copper metal liberated from an exothermic
reaction between powdered copper oxide and aluminum. The exothermic reaction takes place at a theoretical temperature of 4600°F and as a
result, molten copper alloy is created and used to melt the conductors and cast the finished connection. The exothermic reaction takes place in a
semi-permanent graphite mold that will last 50 or more welds if properly cared for. The process is simple and easy to implement providing an on-site
means to make welded electrical connections without requiring external power, equipment or the special training usually required for brazing and
welding. The process will provide a finished connection that will never corrode, loosen or increase in resistance. The finished connection also
provides an ampacity that exceeds that of the conductors being joined.
Application – Connections
• Cable to cable • Cable to ground rod • Ground rod to ground rod
• Cable to steel surface / pipe • Cable to lug • Cable to busbar
• Busbar to busbar • Busbar to ground rod • Busbar to steel surface
• Cable to rebar • Cable to rail • Equipment ground plate
• Aircraft ground receptacle
UltraWeld Pour & Shoot Process
UltraShot Drop-In Process
Step 1:
• Clean and dry conductors and mold
• Insert conductors into mold
Step 1
• Clean and dry conductors and mold
• Insert conductors into mold
Step 2:
• Close handle clamp and lock mold
• Insert disk into mold
Step 2
• Close handle clamp and lock mold
• Insert UltraShot™ drop-in into mold
Step 3:
• Pour weld metal into mold
Step 3
• Attach cord to UltraShot™ igniter
Step 4:
Step 4
• Push and hold both igniter buttons at the same time
• Sprinkle starting material over the weld metal and close lid
• Sprinkle remaining starting material in the ignition pocket on the top of the
TOP-LIGHT lid
Step 5:
• Ignite using the FLTIG flint igniter
Step 5
Step 6:
A completed UltraShot™ connection
• Reaction is made
• Open mold and remove connection
• Remove slag before next connection
• After reaction is complete, open the mold and remove the connection
• Remove slag from the mold before making the next connection
A complete Ultraweld connection
Materials, Tools & Accessories
UltraShot Controller
• Patented copper drop-in cartridge consumed during the reaction
process.
• Rugged long lasting 12-volt rechargeable battery control unit
ignites hundreds of connections on a single charge.
• Cartridge is consumed leaving no waste such as plastic or metal
containers on the job site.
• Long lasting Ultra-reliable ignition process allows for little to no
downtime on the job site.
UltraShot® (Drop-In) Weld Metal
Size
US25
US32
US45
US65
US90
US115
US150
137
Qty. / Ctn
20
20
20
20
10
10
10
Size
US200
US250
US300
US400
US500
US600
US750
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Qty. / Ctn
10
10
10
5
5
5
5
UltraShot Weld Metal
• The weld metal, a mixture of copper oxide and aluminum, is
packaged in individual, moisture resistant copper drop-ins.
• The copper drop-in is consumed during the reaction process.
• Each drop-in is marked with the size.
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Safety and Protection
Ultraweld® (Pour & Shoot) Weld Metal
Size
Qty. / Ctn
UWM15
UWM25
UWM32
UWM45
UWM65
UWM90
Size
20
20
20
20
20
10
UWM115
UWM150
UWM200
UWM250
UWM500
Open Mold
Qty. / Ctn
10
10
10
10
5
UltraWeld Weld Metal
• The weld metal, a mixture of copper oxide and aluminum, is
packaged in individual, moisture resistant plastic cartridges.
• Each cartridge is marked with the size.
• Each box also contains instructions and metal disks.
• One metal disk is used for each connection.
• The plastic box is shrink-wrapped to provide additional moisture protection.
Closed Mold
Molds
• Depending on the care and treatment of the mold, it will average
50 or more welds. Substantially more with the UltraShot process.
• The Ultraweld smokeless process uses an integrated filter system on
the mold and electric ignition of the weld metal to produce a
finished connection with minimal smoke emission. Ideal for indoor
and confined space working conditions.
• For Ultraweld smokeless process, ignition is accomplished with the
use of a USCONTROLLER.
• Mold Handle not included.
Smokeless
Mold
Open Mold
Closed Mold
USCONTROLLER
Smokeless
Mold
Mold Accessories
Flint Igniter
USCONTROLLER
• When making an Ultraweld connection, Flint Igniters are used to
ignite the starting material.
• Flint Igniters comes with MH1 and MH2 handle clamps.
• Torches are required to remove moisture from the mold and
conductors before making the Ultraweld connections.
36" Extension
Torch Head
Cable & Work Surface Preparation
Card Cloth Brush
Cable Cleaning Brush
• Card Cloth Brush has short, stiff, metal bristles which are generally
preferred for cleaning concentric conductors and busbars, that
are not heavily oxidized.
• Cable Cleaning Brush is ideal for cleaning concentric stranded
cable, especially very dirty or oxidized conductors.
• Rasp is ideal for removing mill scale and rust from steel surfaces.
MCBRSH2
MCBRSH1
Rasp
Mold Cleaning Spades
Mold Care & Use
Patented
MCBRSH2
MCBRSH1
• Slag can be removed from molds by using a Mold Cleaning Brush.
• Slag can be cleaned from the molds by using a Mold Cleaning Spade.
• The cleaning spades are specifically designed to fit the mold crucible
for a given range of weld metal sizes.
Disks
• The disk rests on the bottom of the crucible and holds the weld
metal powder in place until the reaction occurs.
• A new disk is required each time a weld is made.
• Disks are included with the Weld Metal.
Chain Support Handle Clamps
Magnetic Support Handle Clamps
Patented
Patented
MH1, MH2
MH3
MH4
Patented
Mold Fastening & Mounting
• Mold Handle Clamps are required for all molds.
• Some molds are used with specialized frames.
• Chain Support Handle Clamps are used to securely hold the mold
to either a vertical or horizontal pipe.
• Magnetic Support Handle Clamp allows mold to be securely held
in place to steel surfaces.
Mold Blanket
• Extends mold life by protecting against shock impact caused by
rough handling.
• Protects exothermic welders from coming into contact with hot
molds; Used as a protection blanket against weld splatter.
Patented
Toolkit
Safety & Protection
Patented
• Toolkit Includes:
TOOLBOX: 22” x 9.5” x 9.75” plastic toolbox with tray; 9” Cable
Cutters; Lineman’s Pliers; 6” Screwdriver; 10” Vise-Grips; Flint Igniter;
Card Cloth Brush; Mold Cleaning Brush; Disk Kit
Patented
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Safety and Protection | Exothermic Welding
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ented
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Safety and Protection
Exothermic Connections
BS
DPRT
RT
DX1C
XX
DPRDT
Cable to Cable
CS
XO
PRPT
PD
PHD
PV
PB
RATD
DX
Cable to Ground Rod
GCU
GV
GU
GD
GSC
GO
GOT
GOXX
GF
GT
Ground Rod to Ground Rod
GG
GRH90B
GRT
GRXO
GRHT
GRS
GROT
Cable to Steel Surface / Pipe
HB
HD
VH
VA
HU
HT
HRT
HTCP
VU
VD
VR
VT
BE
BV
Cable to Lug
LE
LBJ
Cable to Busbar
BCE
BC
BCF
BCX
BU
BD
BL
BTE
BH
BCB
* Please refer to Harger manual for full range of exothermic connections
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Safety and Protection
Busbar to Busbar
BB
BHEBVTT
BT
BA
BBC
BHEBHT
BHFBHX
BMB
GVSP
GHSD
Busbar to Ground Rod
GVSD
GVSO
GVSS
GSSD
GVSAS
GLV
GHSO
Busbar to Steel Surface
BBDVS
BBHTVS
Cable to Rebar
RCB
RE
RO
RB
RS
RP
HRCT
Cable to Rail
RMFPL
RMFT
RMVL
RMVH
Equipment Ground Plate
EGPCB
EGPCT
EGPCVD
EGPBS
EGPGRT
EGPHB
EGPID
EGPIO
FGRGD
FGRGO
FGRBS
FGRIGD
Safety & Protection
Aircraft Ground Receptacle
FGRIGO
* Please refer to Harger manual for full range of exothermic connections
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